US7055597B2 - Method and apparatus for downhole tubular expansion - Google Patents

Abstract

The present invention provides apparatus and methods for expanding tubulars in a wellbore. In one aspect, a process of sealing an annular area in a wellbore is provided in which a tubular having perforations at a predetermined location and a sleeve concentrically covering substantially all of the perforations is expanded into substantial contact with an inner diameter of a tubular, such as a casing or a liner. In another aspect, a process of sealing an annular area in a wellbore is provided in which a tubular having perforation at a predetermined location and a sleeve concentrically coving substantially all of the perforations is expanded into substantial contact with a junction between two tubulars, such as a liner and a casing, or between two liners.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 09/818,119, filed Mar. 27, 2001 now U.S. Pat. No. 6,662,876, and is herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to downhole sealing, and to an apparatus and method for use in forming an arrangement to allow creation of a downhole seal. Generally, the invention relates to the provision of a seal or packer between concentric downhole tubing, such as a bore-lining casing and production casing.

2. Background of the Related Art

In the oil and gas exploration and production industry, bores are drilled to access hydrocarbon-bearing rock formations. The drilled bores are lined with steel tubing, known as casing or liner, which is cemented in the bore. Oil and gas are carried from the hydrocarbon-bearing or production formation to the surface through smaller diameter production tubing which is run into the fully cased bore. Typical production tubing incorporates a number of valves and other devices which are employed, for example, to allow the pressure integrity of the tubing to be tested as it is made up, and to control the flow of fluid through the tubing. Further, to prevent fluid from passing up the annulus between the inner wall of the casing and the outer wall of the production tubing, at least one seal, known as a packer, may be provided between the tubing and the casing. The tubing will normally be axially movable relative to the packer, to accommodate expansion of the tubing due to heating and the like. The packer may be run in separately of the tubing, or in some cases may be run in with the tubing. In any event, the packer is run into the bore in a retracted or non-energized position, and at an appropriate point is energized or “set” to fix the packer in position and to form a seal with the casing. A typical packer will include slips which grip the casing wall and an elastomeric sealing element which is radially deformable to provide a sealing contact with the casing wall and which energizes the slips. Accordingly, a conventional packer has a significant thickness, thus reducing the available bore area to accommodate the production tubing. Thus, to accommodate production tubing of a predetermined diameter, it is necessary to provide relatively large diameter casing, and thus a relatively large bore, with the associated increase in costs and drilling time. Further, the presence of an elastomeric element in conventional packers limits their usefulness in high temperature applications.

Therefore, there is a need to provide a means of sealing production tubing relative to casing which obviates the requirement to provide a conventional packer, by providing a relatively compact or “slimline” sealing arrangement.

Additionally, recent industry trends have demanded the need for expandable tubular systems, where tubulars are expanded in situ. There is a need, therefore, for a packer that utilizes this in situ expansion technology. Also, some applications for packers now require high tensile strength and/or pressure ratings across the seal. These pressure ratings are conceivably as much as 10,000 psi or higher. There is a further need, therefore, for a packer using expandable tubulars that results in an exceptionally high sealing strength.

BRIEF SUMMARY OF THE INVENTION

In one aspect, a method and apparatus for sealing an annular area in a wellbore is provided in which a tubular is placed in the wellbore, the tubular having perforations, or slots, at a predetermined location and a sleeve concentrically covering substantially all of the perforations. Placing an expansion tool in the tubular. Energizing the expansion tool and causing extendable members therein to extend radially to contact an inner wall of the tubular. The tubular is thereby expanded into substantial contact with an inner diameter of a casing or a liner, wherein substantially no gap exists between the sleeve and the casing or the liner.

In another aspect, a process of sealing an annular area in a wellbore is provided in which a tubular is placed in the wellbore at a junction between a casing and a liner or a junction between a liner and another liner. The tubular has perforations, or slots, at a predetermined location and a sleeve concentrically covering substantially all of the perforations. Placing an expansion tool in the tubular. Energizing the expansion tool causing extendable members therein to extend radially to contact an inner wall of the tubular. The tubular is thereby expanded into substantial contact with an inner diameter of the liner and/or casing.

In yet another aspect, a process of sealing an annular area in a wellbore is provided in which a tubular and an expansion tool assembly is placed in the wellbore. The tubular having perforations, or slots, at a predetermined location and a sleeve concentrically covering substantially all of the perforations. Energizing the expansion tool causing extendable members therein to extend radially to contact an inner wall of the tubular. Thereby expanding the tubular into substantial contact with an inner diameter of the liner and/or casing.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.

It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 is a perspective view of an expansion tool of the present invention;

FIG. 2 is a perspective end view in section thereof;

FIG. 3 is an exploded view of the expansion tool;

FIG. 4ais a section view of an embodiment of the invention including an expansion tool disposed on an end of a run-in tubular, a first tubular, a second perforated tubular, o-ring seals, and a bridge plug;

FIG. 4bis a section view of the embodiment shown inFIG. 4a, wherein the second tubular has been partially expanded;

FIG. 4cis a section view of the embodiment shown inFIGS. 4a–b, wherein the second tubular has been expanded and the extension tool removed;

FIG. 5ais a section view of an embodiment of the invention, including an expansion tool disposed on an end of coil tubing, a junction between a first tubular and a second tubular having perforated section;

FIG. 5bis a section view of the embodiment shown inFIG. 5a, wherein the second tubular has been partially expanded;

FIG. 5cis a section view of the embodiment shown inFIGS. 5a–b, wherein the second tubular has been expanded and the extension tool removed;

FIG. 6 is a section view of an embodiment of the invention, wherein the expansion tool disposed on an end of a run-in tubular, and a section of perforated tubular is inserted into a wellbore as an assembly to create a seal between a junction of two tubulars; and

FIG. 7 is a top view of an embodiment of the invention, wherein a second, smaller tubular is partially expanded into a first tubular to hang the second tubular.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention provides apparatus and methods for expanding tubulars in a wellbore.FIGS. 1 and 2 are perspective views of anexpansion tool100 andFIG. 3 is an exploded view thereof. Theexpansion tool100 has abody102 which is hollow and generally tubular withconnectors104 and106 for connection to other components (not shown) of a downhole assembly. Theconnectors104 and106 are of a reduced diameter (compared to the outside diameter of the longitudinallycentral body part108 of the tool100), and together with threelongitudinal flutes110 on thecentral body part108, allow the passage of fluids between the outside of thetool100 and the interior of a tubular therearound (not shown). Thecentral body part108 has threelands112 defined between the threeflutes110, eachland112 being formed with arespective recess114 to hold arespective roller116. Each of therecesses114 has parallel sides and extends radially from the radially perforatedtubular core115 of thetool100 to the exterior of therespective land112. Each of the mutuallyidentical rollers116 is near-cylindrical and slightly barreled. Each of therollers116 is mounted by means of abearing118 at each end of the respective roller for rotation about a respective rotational axis which is parallel to the longitudinal axis of thetool100 and radially offset therefrom at 120-degree mutual circumferential separations around thecentral body108. Thebearings118 are formed as integral end members of radiallyslidable pistons120, onepiston120 being slidably sealed within each radially extendedrecess114. The inner end of each piston120 (FIG. 1) is exposed to the pressure of fluid within the hollow core of thetool100 by way of the radial perforations in thetubular core115. In this manner, pressurized fluid provided from the surface of the well, via a tubular, can actuate thepistons120 and cause them to extend outward and to contact the inner wall of a tubular to be expanded.

FIG. 4ais a section view of an embodiment of the invention including anexpansion tool100 disposed on an end of a run-in tubular410, a perforated or slotted tubular420a, o-ring seals470,475, and abridge plug450. In this aspect, the perforated section of tubular will replace the need for a conventional production packer. Preferably, a tubular420ahaving a thickness that is commensurate with a desired load strength is provided, but has slots orperforations415 in the tubular420a. The slots orperforations415 reduce the tangential strength of the tubular420a, thereby, requiring less work to expand the tubular420athan a solid tubular.

Generally, thewellbore400 has a first tubular, or casing,460 andproduction perforations480 disposed therein. A second tubular of smaller diameter, orproduction tubular440 having a perforated, or slotted, section of tubular420a, and ascreen430 disposed on the end thereof, are run into thecasing460. The perforated tubular420ais connected to theproduction tubular440 by any conventional means.Tubular420ahasperforations415 which may be slots of oval shape, diamond shape, or any other geometry that reduces tensile hoop stresses, and asleeve425 concentrically covering substantially all of theperforations415. Thesleeve425 is made of a ductile material, such as copper, stainless steel, tempered chrome, or a thermoplastic, and has an elastomer outer coating, orskin435. The sleeve may be shouldered into position or welded into position. Afirst sealing member470, such as an o-ring, concentrically covers a top portion of the outer diameter of thesleeve425, and asecond sealing member475 concentrically covers a bottom portion of the outer diameter of thesleeve425.

Theexpansion tool100 is run into the tubular440,420aby a run-in tubular410, or coil tubing, which may also be used to provide electrical power and hydraulic fluid to theexpansion tool100. Referring again toFIG. 1, fluid pressure to actuate therollers116 of theexpansion tool100 is provided from the surface of the well through a run-in tubular410, or coiled tubing string. Theexpander tool100 includes at least one aperture101 at a lower end thereof. Aperture101 permits fluid to pass through the apparatus and to circulate back to the surface of the well.

The tubular disposed around the apparatus of the present invention could be a piece of production tubing, or liner or slotted liner which requires either the expansion of a certain length thereof or at least a profile formed in its surface to affix the tubular within an outer tubular or to facilitate use with some other downhole tool. InFIG. 4a, theannulus490 between the tubular440,420aand thewellbore400 could be a void or could be filled with non-cured cement.

In use, theexpansion tool100 is lowered into thewellbore400 to a predetermined position and thereafter pressurized fluid is provided in the run-intubular410. In the preferred embodiment, some portion of the fluid is passed through an orifice or some other pressure increasing device and into theexpansion tool100 where the fluid urges therollers116 outwards to contact the wall of the tubular420atherearound. Theexpansion tool100 exerts forces against the wall of a tubular420atherearound while rotating and, optionally, moving axially within thewellbore400. The result is a tubular that is expanded past its elastic limits along at least a portion of its outside diameter. Gravity and the weight of the components urges theexpansion tool100 downward in thewellbore400 even as therollers116 of theexpander tool100 are actuated. The expansion can also take place in a “bottom up” fashion by providing an upward force on the run-in tubular string. A tractor (not shown) may be used in a lateral wellbore or in some other circumstance when gravity and the weight of the components are not adequate to cause the actuatedexpansion tool100 to move downward along thewellbore400. Additionally, the tractor may be necessary if thetool100 is to be used to expand the tubular420awherein the tractor provides upward movement of theexpansion tool100 in thewellbore400.

At an upper and a lower end of theexpansion tool100 shown inFIGS. 4a–b,5a–band6 are a plurality of non-compliant rollers constructed and arranged to initially contact and expand a tubular prior to contact between the tubular and fluid actuatedrollers116. Unlike the compliant, fluid actuatedrollers116, thenon-compliant rollers103 are supported only with bearings and they do not change their radial position with respect to the body portion of thetool100.

FIG. 4bis a section view of the embodiment shown inFIG. 4a, wherein the tubular420bhas been partially expanded by theexpansion tool100 into an inner diameter of thecasing460.

FIG. 4cis a section view of the embodiment shown inFIGS. 4a–b, wherein the tubular420chas been expanded into thecasing460 and theextension tool100 removed. The junction between the tubular420cand the inner diameter of thecasing460 has been substantially sealed and is structurally supported in this manner. Sealingmembers470, and475 further reinforce the seal at the top and bottom portions of the outer diameter of thesleeve425 creating a “zero interference fit” between the tubular420cand thecasing460. Thesleeve425 is essentially sandwiched between the inner diameter of thecasing460 and the outer diameter of theperforated tubular420c. Preferably, no gap exists between thesleeve425 and thecasing460. With thecasing460 now supporting thesleeve425, the collapse strength of thesleeve425 and tubular420ais enhanced because the material must shear to fail rather than buckle. The constrained tubular420chas a collapse strength of about two and a half times of the unexpanded tubular420a. Additionally, the constrained tubular420cand sealingmembers470, and475 can withstand pressure exerted in theannulus490 above and below the junction, as well as the constrained tubular420c, or combinations thereof, of up to about 10,000 psi. It is also contemplated that this aspect of the invention would have valuable application at higher pressures of up to about 15,000 psi, such as in deep water operations.

FIG. 5ais a section view of an embodiment of the invention, including anexpansion tool100 disposed on an end ofcoil tubing510, or a run-in tubular, ajunction530 between afirst tubular560, such as a casing or a liner, and asecond tubular540 having a perforated or slottedtubular section520a. In this aspect, the perforated section of tubular will replace the need for a conventional liner top packer.

Generally, thewellbore500 has afirst tubular560, such as a casing or a liner. A second tubular of smaller diameter, orliner540, having a perforated, or slotted, section of tubular520adisposed at the top end thereof is run into thefirst tubular560. The perforated tubular520ais connected to the second tubular520 by any conventional means and is made of the same material described in reference toFIGS. 4a–c. The perforated tubular520ahas perforations orslots515, asleeve525 substantially covering the perforations, and anouter skin535. Theliner540 is set with aconventional hanger assembly580.

Amud motor590 provides rotational forces to theexpansion tool100. The structure of the mud motors is well known. The mud motor can be a positive displacement Moineau-type device and includes a lobed rotor that turns within a lobed stator in response to the flow of fluids under pressure in the coiledtubing510. Themud motor590 provides rotational force to rotate theexpansion tool100 in thewellbore500 while therollers116 are actuated against an inside surface of the tubular520a. Pressurized fluid passes through themud motor590 providing rotational movement to an output shaft (not shown) that is connected to theexpansion tool100 to provide rotation thereto. Alternatively, theliner540 may be set by running theliner540 and theexpansion tool100, disposed on an end of a run-in tubular, into thewellbore500 as an assembly (as shown inFIG. 6 and further discussed below). It should be understood that a coil tubing and mud motor may be used with the embodiments of the invention described inFIGS. 4a–c, as well.

FIG. 5bis a section view of the embodiment shown inFIG. 5a, wherein the perforated section oftubular520bhas been partially expanded into thefirst tubular560. Theperforated tubular520b, disposed above the solid section oftubular540, is expanded until theperforated tubular520b,sleeve525, and sealingmembers570, and575 are in substantial contact with the inner diameter of thefirst tubular560.

FIG. 5cis a section view of the embodiment shown inFIGS. 5a–b, wherein theperforated section520cof thesecond tubular540 has been expanded into thefirst tubular560 and theexpansion tool100 removed. Thereby sealing thejunction530 between the first andsecond tubulars560,540. Preferably, there is no gap between thesleeve525 and thefirst tubular560.

FIG. 6 is a section view of an embodiment of the invention, wherein theexpansion tool100 and asecond tubular540 having a section of perforated tubular520aare placed into a wellbore as an assembly to create a seal between ajunction530 of two tubulars. Theexpansion100 is disposed within the second tubular and held therein with a temporary,shearable connection610. In one embodiment, thetool100 and the tubular540 are run into thewellbore500 on a run-in tubular620 which provides hydraulic fluid to the tool. The tubular540 is then set by any conventional means or as described below with reference toFIG. 7. Theconnection610 is sheared by an upward force on the run-in tubular, the tool energized, and the perforated tubular520aexpanded.

FIG. 7 is a top section view of an embodiment of the invention, wherein a second, smaller tubular540, or liner, is partially expanded into a first tubular560 to temporarily hang the second tubular. This embodiment is especially useful to set a liner in a wellbore without the use of a conventional liner hanger. To set theliner540, theexpansion tool100 is energized and radially expands one ormore sections710 of thesecond tubular540, disposed below the perforated section of tubular520a, into thefirst tubular560, thereby fixing theliner540 in the wellbore. Theunexpanded sections720 of tubular540 allow for the passage of fluid, such as cement. Depending upon the requirements of the operator, a fluid path may be left between the expanded tubular and the wellbore in order to provide a flow path for fluids, including cement. For example, the tubular may be expanded in a spiral fashion leaving flute-shaped spaces for the passage of cement or other fluids. The perforated section of tubular520ais then expanded to create a seal between the two tubulars. Optionally, thesecond tubular540 may be expanded to smooth out the one ormore sections710 after cementing and thetubulars540 and520amay then be expanded in a “bottom-up” fashion. It should be understood that the method described herein is especially useful in the embodiments ofFIGS. 5a–cand6.

While the foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims (34)

1. An apparatus for sealing an annular area formed between the apparatus and a wellbore therearound, comprising:

a tubular having a weakened section with reduced tangential strength; and

a sleeve covering at least part of the weakened section, wherein the sleeve has an outer diameter larger than an outer diameter of the tubular such that first and second ends of the sleeve form respective circumferential outward facing shoulders, whereby the apparatus is expandable to form a seal with the wellbore the seal extending along substantially the length of the sleeve from the first end to the second end.

2. The apparatus ofclaim 1, further comprising first and second seals disposed on the outside surface of the sleeve.

3. The apparatus ofclaim 2, wherein the seals comprise o-rings.

4. The apparatus ofclaim 1, further comprising a hanger assembly to set the tubular in another tubular in the wellbore.

5. The apparatus ofclaim 1, wherein the sleeve covers substantially all of the weakened section.

6. The apparatus ofclaim 1, wherein at least a portion of the outside surface of the sleeve contacts the wellbore therearound when the apparatus is expanded.

7. The apparatus ofclaim 1, wherein the sleeve comprises an elastomer outer coating.

8. The apparatus ofclaim 1, wherein the sleeve comprises a ductile material selected from at least one member of the group consisting of copper, stainless steel, tempered chrome and a thermoplastic.

9. The apparatus ofclaim 1, further comprising an expander tool and a shearable connection connecting the expander tool to the tubular.

10. A method of sealing an annular area in a wellbore, comprising:

placing a tubular in the wellbore, the tubular having a weakened section with reduced tangential strength and a sleeve concentrically covering at least part of the weakened section, wherein the weakened section defines a reduced outer diameter of the tubular; and

utilizing the weakened section to expand the tubular and the sleeve, wherein at least a portion of the sleeve is expanded into substantial contact with an inner diameter of the wellbore to form a seal with the wellbore along substantially an entire length of the sleeve after expansion thereof.

11. The method ofclaim 10, wherein a bridge plug is disposed below the tubular.

12. The method ofclaim 10, wherein the wellbore is lined with a casing.

13. The method ofclaim 10, wherein the wellbore is lined with a liner.

14. The methodclaim 10, further comprising hanging the tubular in the wellbore by radially expanding one or more non-weakened sections of the tubular into contact with an inner diameter of the wellbore.

15. A method for forming a junction between a first tubular and a second tubular in a wellbore, comprising:

setting a hanger assembly to connect an upper portion of a first tubular within a lower portion of a second tubular, the first tubular having apertures in a wall thereof at a predetermined location and a sleeve concentrically covering substantially all of the apertures, wherein the predetermined location defines a reduced outer diameter of the tubular;

applying a radial force to the first tubular to expand the first tubular and the sleeve, wherein at least a portion of the sleeve is expanded into substantial contact with an inside surface of the second tubular to form a seal with the second tubular along substantially an entire length of the sleeve after expansion thereof.

16. The method ofclaim 15, wherein at least a portion of the tubular is also expanded into substantial contact with the inside surface of the second tubular.

17. The method ofclaim 15, wherein the apertures are in at least a portion of the upper portion of the first tubular concentrically positioned within the second tubular.

18. The method ofclaim 15, wherein the second tubular is a casing.

19. The method ofclaim 15, wherein the second tubular is a liner.

20. The method ofclaim 15, further including circulating cement between the tubulars.

21. An apparatus for sealing an annular area formed between the apparatus and a wellbore therearound, comprising:

a tubular having apertures in a wall thereof at a predetermined location, wherein the predetermined location defines a reduced outer diameter of the tubular; and

a sleeve covering substantially all of the apertures, whereby a length of the apparatus is expandable by a radial outward force applied to an inner wall of the tubular, and wherein the sleeve substantially blocks flow through the apertures and forms a seal with the wellbore along substantially an entire length of the sleeve after expansion thereof.

22. The apparatus ofclaim 21, further comprising first and second seals disposed on the outside surface of the sleeve.

23. The apparatus ofclaim 22, wherein the seals comprise o-rings.

24. The apparatus ofclaim 23, further comprising an expander tool and a shearable connection connecting the expander tool to the tubular.

25. The apparatus ofclaim 21, further comprising a hanger assembly to set the tubular in another tubular in the wellbore.

26. The apparatus ofclaim 21, wherein the apertures are diamond slots or oval slots.

27. The apparatus ofclaim 21, wherein at least a portion of the outside surface of the sleeve contacts the wellbore therearound when the apparatus is expanded.

28. The apparatus ofclaim 21, wherein the sleeve comprises an elastomer outer coating.

29. The apparatus ofclaim 21, wherein the sleeve comprises a ductile material selected from at least one member of the group consisting of copper, stainless steel, tempered chrome and a thermoplastic.

30. A method of sealing an annular area in a wellbore, comprising:

placing a tubular in the wellbore, the tubular having apertures at a predetermined location and a sleeve concentrically covering substantially all of the apertures, wherein the sleeve has an outer diameter larger than an outer diameter of the tubular such that first and second ends of the sleeve form respective circumferential outward facing shoulders; and

operating an expander to expand the tubular and the sleeve, the sleeve substantially blocking flow through the apertures to further seal the annular area along substantially a length of the sleeve from the first end to the second end after the sleeve is expanded into substantial contact with the inner diameter of the wellbore.

31. The method ofclaim 30, further comprising hanging the tubular in the wellbore by radially expanding one or more non-perforated sections of the tubular into contact with the inner diameter of the wellbore.

32. The method ofclaim 30, wherein a bridge plug is disposed below the tubular.

33. The method ofclaim 30, wherein the wellbore is lined with a casing.

34. The method ofclaim 30, wherein the wellbore is lined with a liner.

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